WO2008129361A2

WO2008129361A2 - Hockey stick system having a multiple tube structure with an insert

Info

Publication number: WO2008129361A2
Application number: PCT/IB2007/051430
Authority: WO
Inventors: Roberto Gazzara; Mauro Pinaffo; Mauro Pezzato; Michele Pozzobon; Stephen J. Davis
Original assignee: Prince Sports, Inc.
Priority date: 2007-04-19
Filing date: 2007-04-19
Publication date: 2008-10-30
Also published as: WO2008129361A3

Abstract

A handle is adapted to be held by a player and a striking end is adapted to contact and propel an object. A structure for a hockey stick is described by using multiple composite tubes bonded to one another, wherein openings (58) are molded between the tubes and inserts (27) are positioned in the openings to improve the stiffness, strength, aerodynamics and comfort of the hockey stick.

Description

HOCKEY STICK SYSTEM HAVING A MULTIPLE TUBE STRUCTURE WITH

AN INSERT

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DESCRIPTION

BACKGROUND OF THE INVENTION

The present invention relates to a composite structure for a hockey stick.

Hockey stick systems have traditionally been made from wood. Wood has been a convenient and traditional material to use but is limited in strength and weight. The wood stick is solid and can be made from a multiple ply lamination in order to improve strength.

Recent developments have improved hockey sticks by making them out of metal such as aluminum. Such sticks are typically made from a one piece extruded aluminum tube to which can be attached a blade and handle. The tubular construction offers a lighter weight and also easy attachment for the blade and handle.

More recent developments have advanced hockey stick performance by using composite materials such as fiber reinforced resins such as carbon fiber in an epoxy resin. These sticks are tubular in form to maximize strength and minimize weight.

Composite materials are attractive alternatives to wood, because there exists a large selection of fiber types and resin types, the combinations of which can produce a multitude of options suitable for replacement to wood. These composite laminates have the advantage of being stiffer, stronger, and less susceptible to environmental changes than wood.

Commonly owned European application EP06114348.3 describes a hockey stick system having a multiple tube structure with apertures or ports molded in to provide additional strength, vibration damping, and improved aerodynamics.

Commonly owned European application EP06114644.5 describes a hockey stick system having a single tube structure with apertures or ports molded in to provide additional strength, vibration damping, and improved aerodynamics.

The present invention describes an alternative design where an insert structure is first formed in a separate molding operation then inserted between composite tubes to form a hockey stick system which has the benefits of additional strength, vibration damping, and improved aerodynamics.

Inserts used in the prior art for hockey sticks include the following patents. U.S. Pat. No. 4,343,468 to Lindgren describes a hockey stick wherein the blade embodies a replaceable insert.

U.S. Pat. No. 4,570,932 to Cote describes a hockey blade with a wedge insert to create a curved blade.

U.S. Pat. No. 5,603,498 to Crawford and Davis describes a field hockey stick with an area opposite the striking portion for receiving a resilient pad.

U.S. Pat. No.6,361,451 to Masters and van Schoor decribes a shaft with an internal mechanism to change the stiffness of the shaft.

U.S. Pat. No. 7,108,618 to Frischmon, et.al., describes an insert used to repair a hockey stick shaft.

U.S. Pat. App. No. 2003/0119612 to Goldsmith and DeLap describes a hockey blade with an internal insert.

None of the prior art describes a hockey stick system wherein an insert is integrated into a multiple tube shaft. Therefore there exists a continuing need for an improved hockey stick system. In this regard, the present invention substantially fulfills this need.

SUMMARY OF THE INVENTION

The present invention is a hockey stick where the structure is generally tubular and the traditional single tube is replaced with multiple continuous tubes, preferably a pair of tubes fused together along their facing surfaces to provide an internal reinforcing wall as well as openings into which an insert is positioned between the tubes to provide specific performance advantages.

In particular, the basis of the design is to replace a single tube portion with a double tube design while maintaining the same or similar geometric exterior shape of the original single circular tube design. This provides a structure with an internal wall between the tubes which has strength and stiffness advantages. In addition, the tubes can be separated at various locations forming openings into which an insert is positioned which can provide improved control, comfort, strength, and aerodynamic benefits.

The hockey stick system according to the present invention substantially departs from the conventional concepts and designs of the prior art and in doing so provides an apparatus primarily developed for the purpose of improved control, comfort, strength, aerodynamics, and appearance.

In view of the foregoing commonality inherent in the known types of hockey sticks of known designs and configurations now present in the prior art, the present invention provides an improved hockey stick system.

There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims attached.

In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of descriptions and should not be regarded as limiting.

As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.

The present invention provides a new and improved hockey stick system which may be easily and efficiently manufactured.

The present invention provides a new and improved hockey stick system which is of durable and reliable construction.

The present invention provides a new and improved hockey stick system which may be manufactured at a low cost with regard to both materials and labor.

The present invention provides a new and improved hockey stick system that can provide improved control and comfort.

The present invention further provides a hockey stick system that can provide specific stiffness zones at various orientations and locations along the length of the shaft.

The present invention provides an improved hockey stick system that has improved strength and fatigue resistance. The present invention provides an improved hockey stick system that has improved shock absorption and vibration damping characteristics.

The present invention provides an improved hockey stick system that has improved aerodynamics.

The present invention provides an improved hockey stick system that has a unique look and improved aesthetics.

Lastly, the present invention provides a new and improved hockey stick system made with a multiple tube design, where the tubes, which are fused together along much of their lengths, are separated from one another at selected locations forming openings and inserts are positioned in such openings providing improved means of adjusting stiffness, resiliency, strength, comfort, and aerodynamics.

For a better understanding of the invention and its advantages, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated preferred embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a front elevational view of a hockey stick system, shaft and blade, constructed in accordance with the principles of the present invention.

Figure 2 is an exploded front elevational view of the hockey stick system shown in Figure 1.

Figure 3 is an enlarged front elevational view of the hockey stick system shown in Figure 1 illustrating the opening in greater detail.

Figures 3 A and 3B are cross sectional views taken along lines 3A-3A and 3B-3B of in Figure 3.

Figure 4 is an enlarged front elevational view illustrating an insert for use in the handle.

Figures 5A-5D show various shapes of openings which may be formed in the handle for receiving an insert.

Figure 6 is an isometric view of a portion of the shaft showing the various laminates used.

Figure 7 is a front elevational view of a hockey stick system, shaft and blade, constructed in accordance with an alternate embodiment of the present invention.

Figure 8 is an end view of the bottom of the handle of an embodiment of the invention, after being removed from the mold.

Figure 9 is a cross-section of a handle which is formed of four tubes, corresponding to the location of Figure 3 A. Figure 10 is a cross-section of the handle of Figure 9, corresponding to the location of Figure 3B.

Figure 11 is a cross-section of the handle of Figure 9, corresponding to the location of Figure 3B, showing an alternate embodiment.

Figure 12 is an isometric view of an insert corresponding to the location shown in Figure 11.

Figure 13 is an isometric view of an alternative construction.

Figure 14 is another isometric view of the alternative described in Figure 13.

Figure 15 is a longitudinal cross-section of the lower end of the handle showing an alternate construction.

The same reference numerals refer to the same parts throughout the various Figures.

DETAILED DESCRIPTION OF THE INVENTION

With greater reference to Figures 1 through 6 of the drawings, the present invention is a composite hockey stick system 10. The system features geometric shapes in the shaft for improving the flexibility, strength and other playing characteristics of the system. The system comprises a handle 12 and a striking end 34, i.e., a blade. As exemplified in Figure 6, the stick handle 12 is fabricated of multiple layers of aligned carbon filaments 14 and 36 held together with an epoxy binder 16. The fibers in the various plies are parallel to one another, but the various plies preferably have varying fiber orientations. A woven fabric or braid may also be used.

The stick handle 12 has a long generally hollow rectangular configuration with a top end 18, a bottom end 20, a front face 22, a bottom face 24, and a pair side faces 26. As shown in Figure

3A, the stick handle has a central wall 28 running vertically and generally parallel with the side faces forming two adjacent tubes 30 with hollow interiors along the extent of the stick handle end.

The stick has a recessed opening 32 in the bottom end 20 thereof.

The stick striking end 34 is preferably also fabricated of multiple layers of aligned carbon filaments

14 and 36 held together with an epoxy binder 38, as illustrated by generally Figure 6 (however, the plies of the blade may have different fiber orientations than the handle). The blade may also use woven or braided carbon fibers.

The stick striking end 34 has a generally thin rectangular configuration with a first face 40, a second face 42, an upper edge 44, a lower edge 46, a near end 48, and a far end 50. The near end has a bend 52 at an angle between 45 degrees and 80 degree and being preferably 65 degrees measured between the side faces of the stick handle end and the upper edge and the lower edge. The near end 48 of the stick striking end has a male fitting 54 extending outwardly therefrom, with the fitting 54 being adapted to couple into the opening 32 in the bottom end of the stick handle end 20.

An adhesive 56 couples the stick handle with the stick striking end between the connecting bar and the opening in the stick handle end.

The stick handle end and the stick striking end are configured together to form a shaft which is generally linear in shape.

At least one opening 58 is formed in the stick handle, preferably near the bottom end 20. The opening extends between the front face and the bottom face. Each opening is preferably oval in shape, with the long axis of the oval in line with the vertical axis of the shaft. Each opening includes an interior wall defining an associated hole. The openings separate the adjacent portions of the tubes of the shaft creating openings of increased surface area.

Positioned in each of the apertures 58 are inserts 27. The outer walls 33 of the inserts 27 preferably match the interior walls 59 of the openings 58. The inserts 27 are formed separately from the stick handle. The inserts 27 may be formed of a variety of materials depending on the performance desired. For example, the inserts may be molded of fiber reinforced plastics such as carbon fiber reinforced nylon made from an injection molding process. Another option is mold the insert of an elastomeric material such as thermoplastic polyurethane(TPU) if more flex or vibration damping is desired.

The inserts 27 preferably have holes 29 molded into the insert. The holes 29 are preferably oval in shape and connect one side of the insert to the opposing side.

In the exemplary embodiment shown in Figures 3-4, the handle 12 is formed of two tubes 23 and

25, in a process described further below. Portions of the two tubes 23, 25 form an outer wall of the handle 12. In addition, other portions of the tubes bond together, forming the interior wall 28.

However, at the locations of the openings 58, the facing surfaces 59 of the two tubes 23, 25 are separated from one another, thereby forming the openings 58. The insert 27 has outer walls 33 which contact the interior facing surfaces 59 of the openings 58.

In the embodiment of Figures 1-3, the interior wall 28 and openings 58 are oriented in the direction in which the hockey stick is swung. Alternatively, the interior wall 28 and openings 58 may be oriented perpendicular to such direction. Figures 5A-5D illustrate some examples of the variety of shapes possible to be used for the openings. Depending on the performance required of the structure at a particular location, more decorative opening shapes can be used. The shape of the insert positioned in the opening would follow such shape.

Also, the handle may be formed with more than two tubes. For example, the handle may be formed with four tubes, as shown in Figure 9. As shown, four tubes 61, 62, 63, 64 form interior reinforcement walls that extend both in the direction of the swing and perpendicular to such direction. Using four tubes provides the option of forming openings 58a either in the direction of the swing, as shown in Figure 10, by separating tubes 61 and 62 from tubes 63, 64, or perpendicular to such direction (by separating tubes 61 and 64 from tubes 62 and 63). If desired, four openings 64a-3 may be formed, as shown in Figure 11, by separating all of tubes from one another. The multiple openings shown in Figure 11 would accommodate the insert 35 shown in Figure 12. The insert 35 is shown with holes 37 oriented in the direction of the swing. It is also possible to orient the holes perpendicular to such direction.

An alternate embodiment of the invention is illustrated in Figure 7. Such embodiment is a one piece hockey stick with its handle stick 12 and striking stick end 34 fabricated with an opening 58 there through. An insert 27 with apertures 29 is positioned in the opening 58. In this alternative embodiment a portion the hockey stick handle 12 is preferably made of metal, preferably aluminum, which is fused to a composite portion. It is understood that this embodiment could also be completely constructed of a fiber reinforced composite.

As described below, the hockey stick is formed of two or more tubes which are molded together. Along most of the length of the handle 12, portions of the tubes fuse together during molding to form the common wall 28 (or walls, in the case of more than two tubes). However, at selected locations, the facing surfaces 59 of the tubes are kept apart during molding, to form the openings 58. As shown in Figure 3, on either side of the openings 58, the tubes are joined together. These openings are formed without drilling any holes or severing any reinforcement fibers. The resulting structure is found to have unique performance characteristics. The openings are preferably oval in shape with the longitudinal dimension longer than the width dimension in the ratio range of 2: 1 to 8:1, and preferably in the range of 3: 1 to 5: 1. The longer openings allow the tubes to twist more when the puck contacts the blade. This facilitates catching the puck, called trapping.

The long openings also create a more flexible bending zone which is also desirable in the lower portion of the stick handle.

The long openings allow local flexure of the tubes which resists the impact blows resulting from slashing from other sticks.

The inserts can vary in stiffness to vary the performance of the stick handle in the zone where the inserts are located. The inserts can be molded of a stiff material such as carbon fiber reinforced polymer. An alternative choice would be to mold the inserts out of an elastomeric material such as

TPU that would not contribute to the stiffness of the stick handle, but would improve the vibration damping and feel of the hockey stick.

The inserts can improve the control of the hockey stick by limiting torsional deformation when trapping the puck. This can be done by changing the shape of the insert, the material used, and the presence of apertures in such insert. This allows the puck to stay on the face of the blade rather than bouncing off the blade face.

The inserts can also improve the comfort of the hockey stick in a similar manner. If the inserts are made of a softer material than the stick handle, or made of a viscoelastic material such as a thermoplastic, they can be effective in absorbing shock before it reaches the hands of the hockey player.

The inserts can be formed with apertures or holes for improved strength and aerodynamics. The holes are preferably in the shape of double opposing arches which allow the structure to deflect which deforms the holes, and return with more resiliency. The holes also allow greater bending flexibility than would traditionally be achieved in a single tube design. The structure can also improve comfort by absorbing shock and damping vibrations due to the deformation of the holes.

Finally, the holes can improve aerodynamics by allowing air to pass through the shaft to reduce the wind resistance and improve maneuverability.

The process to produce the hockey stick handle of the present invention is using a bladder molding process which is described below. Pultrusion processes which are used to make constant cross sections are not suitable for use in making the present invention because of the geometric change in shaft design along the length of the shaft. With the present invention, openings are molded at at least one location along the length of the shaft therefore requiring a specific molding technique. Each tube is preferably made from a long fiber reinforced prepreg type material. Traditional lightweight composite structures have traditionally been made by preparing an intermediate material known as a prepreg which will be used to mold the final structure. A prepreg is formed by impregnating the fibers, such as carbon, glass, and others, with resin. This is typically done using a prepreg machine, which applies the non-cured resin over the fibers so they are all wetted out. The resin is at an "B Stage" meaning that only heat and pressure are required to complete the cross linking and harden and cure the resin. Traditionally, thermoset resins like epoxy are popular because they are available in liquid form at room temperature, which facilitates the impregnation process. A thermoset is created by a chemical reaction of two components, forming a material in a nonreversible process. Usually, the two components are available in liquid form, and after mixing together, will remain a liquid for a period of time before the crosslinking process begins. It is during this "B Stage" that the prepreg process happens, where the resin coats the fibers. Common thermoset materials are epoxy, polyester, vinyl, phenolic, polyimide, and others. The prepreg sheets are cut and stacked according to a specific sequence, paying attention to the fiber orientation of each ply, as illustrated generally by Figure 6. Generally is it desirable to have a symmetrical sequence, meaning that in the final laminate, the same fiber orientation is present above and below the centerline of the laminate, at the same distance. Each ply will have a specific fiber orientation depending on the performance required.

Each prepreg layer comprises an epoxy resin combined with unidirectional parallel fibers from the class of fibers including but not limited to carbon fibers, glass fibers, aramid fibers, and boron fibers.

The prepreg is cut into strips at various angles and laid up on a table. The strips are then stacked in an alternating fashion such that the fibers of each layer are different to the adjacent layers. For example, one layer may be +30 degrees, the next layer -30 degrees. If more bending stiffness is desired, a lower angle such as 20 degrees can be used. If more torsional stiffness is desired, a higher angle such as 45 degrees can be used. In addition, 0 degrees can be used for maximum bending stiffness, and 90 degrees can be used to resist impact forces and to maintain the geometric structural shape of the tube.

This layup, which comprises various strips of prepreg material, is then rolled up into a tube. A thin walled polymeric bladder is then inserted into the tube. This bladder will be used to internally inflate the tube when placed in the mold.

Another similar tube is prepared. The two tubes are then packed into a mold which forms the shape of the hockey stick. The two tubes are positioned side by side so that the common wall between the tubes is the short dimension of the rectangular shaped cross section of the shaft. If the mold and tubes are longer than the final desired dimension of the hockey stick, a final cut to length operation can be performed on the handle 12 after molding.

Air fittings are applied to the interior of the bladder on each end of each tube. The mold is then closed over the tubes and placed in a heated platen press. For epoxy resins, the temperature is typically around 350 degrees F. While the mold is being heated, the tubes are internally pressurized which compresses the prepreg material and cures the epoxy resin. Once cured, the mold is opened and the part is removed.

In order to form the openings, the mold will have pins positioned in the mold, between the two tubes, to keep the tubes separated and thereby to form these openings. The pins can be positioned on the top and bottom portions of the mold. The procedure would be to pack the first tube into the bottom part of the mold. The second tube is then placed next to the first tube with the pins positioned between the tubes. Finally, the top portion of the mold is positioned and the mold is closed. If desired, additional reinforcement can be wrapped around each pin prior to placing in the mold.

When the mold is heated up and air pressure is applied, the prepreg material becomes soft and conforms around each pin. Once cured, the mold is opened in the reverse sequence of packing.

Particular attention is needed when removing the top mold portion to ensure that all pins are pushed out in a linear fashion. Once the pins are removed from the part, the part can be removed from the bottom portion of the mold.

The composite material used is preferably carbon fiber reinforced epoxy because the objective is to provide reinforcement at the lightest possible weight. Other fibers may be used such as fiberglass, aramid, boron and others. Other thermoset resins may be used such as polyester and vinyl ester.

Thermoplastic resins may also be used such as nylon, ABS, PBT and others.

Manufacturing the inserts separately from the stick handle has several advantages. It may be desirable for the insert to have different performance characteristics than the hockey shaft, such as a different stiffness or vibration damping characteristics. Molding the holes into the insert can be less expensive than forming them using carbon composites, which can be a laborious process. Efficient processes such as injection molding or compression molding using bulk molding compounds are alternatives among others. Utilizing a different material than the stick handle may also provide performance benefits. For example, using a viscoelastic polymer such as a thermoplastic based material would provide improved vibration damping and shock absorption. It is also possible to use a metal insert to improve stiffness or strength, or for aesthetic purposes. The result is a unique hockey stick handle structure. The internal wall resulting from the multiple tubes adds strength because it helps prevent the tube from collapsing during bending. Hollow tubes are susceptible to buckling failure when being flexed to extreme amounts. This is because when being flexed, a portion of the tube is under compressive forces, and the thin wall of the tube can buckle. With the internal wall, this significantly improves flexural strength by preventing the wall of the tube from buckling.

The hockey stick system of the present invention becomes more unique when the openings are molded in the structure. The uniqueness is further advanced with inserts positioned in the openings. The uniqueness is even further advanced with holes or apertures formed in the inserts. It is not necessary to change the exterior dimensions of the shaft when molding openings and using inserts with holes. Therefore, the shaft becomes much more aerodynamic because the frontal area is significantly reduced. This is a great benefit to a hockey stick system. The hockey stick is long in length and can be difficult to generate fast swing speeds. For example, compared to a golf shaft which is about the same length, the hockey stick system is about four times to about six times greater in frontal area, therefore being much less aerodynamic.

Having aerodynamic apertures in the hockey shaft can significantly reduce aerodynamic drag. The size and spacing of each aperture can vary according to desired performance parameters. The orientation, or axis of the apertures is in line with the swing direction of the shaft therefore maximizing the aerodynamic benefit.

The size and spacing of the openings can affect shaft stiffness in a desirable way. These openings can direct the flexpoint of the shaft toward the lower portion of the shaft if desired. A hockey stick system with a lower flex point is said to provide more velocity to the shot. The effect of the openings can be further enhanced by using inserts of different constructions, with or without holes. An unexpected benefit of the openings in the shaft is that they actually improve the durability and strength of the shaft. No fibers are severed forming the openings. The shape of the openings act as arches to distribute the stress and strain in a very efficient manner. The inserts can provide reinforcement at specific locations within each opening. During a typical hockey shot, the blade of the hockey stick contacts the ice with significant force, which induces an "out of plane" bending and twisting on the shaft. The molded openings in the shaft allow more flex in this direction, and the inserts can control that deflection, which can improve the fatigue resistance of the shaft. A design modification is used in order to bond a hockey shaft of the present invention to a typical blade. A typical hockey blade has a fitting 54 that fits inside the opening 32 of the lower end 20 of the handle 12. The fitting 54 would not fit if the internal wall 28 were to extend all the way to the lower end 20. Therefore, it is necessary to modify the internal structure in the region of the lower end 20 in order to receive the fitting 54. This can be done several ways.

One option is to have two different prepreg tube lengths. One tube would be the full length of the shaft, and the other would start at a point some distance from one end and then continue to the full length of the other end. The joint area where the shorter tube connects to the longer tube will typically require extra reinforcement which is not a problem with fiber reinforced composites. A second option is to manufacture the hockey shaft of the present invention using three tubes. Two tubes will be of equal construction and length. Both will be slightly shorter than the full length of the shaft. Then a third tube is positioned over both tubes on one end. The bladders of both internal tubes continue out the back of the third tube. When inflated, the bladders will compress each of the longer tubes as well as the over wrapped third tube creating a unified structure. Again, as with the first option, additional reinforcement may be required in this joint region.

A third option is to use a coupling, or a third part sleeve, to bond the hockey shaft of the present invention to the blade. In this case, the tip region of the shaft shall be molded of an exterior shape equal to that of the blade portion. Then a tubular sleeve of short length can be positioned over both the blade portion and shaft portion and bonded into place.

A fourth option is illustrated in Figure 8. As shown there, during molding, a socket-forming member 31 is inserted between the tubes 23, 25 in the longitudinal direction. The socket forming member 31 extends up between the tubes 23, 25 for a distance which is at least as long as the fitting 54. After molding, the member 31 is withdrawn, leaving the socket 32. Although the member 31 is shown as having a generally rectangular cross section, any cross-sectional shape may be used, provided it corresponds to the cross-section of the fitting 54.

A fifth option is shown in Figure 15 which shows a longitudinal cross section of the shaft in the area of the opening. Here, a single long tube 95 begins at the upper end of the handle, continues toward the lower end and once past the last opening, reverses direction and returns back to the upper end on the other side of the openings. This creates a "hairpin" shaped tube where the "U" portion of the hairpin forms an internal wall 96 creating an interface between the area 97 of the opening and the lower blade receiving area 98. The blade receiving area 98 is formed by a single tube 99 which has an internal geometry to accept the fitting 54.

The internal wall 90 formed in the handle area can vary in length outside the area of the opening. For example, the internal wall 90 can terminate shortly after the first opening 91 , leaving a single tube for the remaining portion of the shaft.

It is also possible to design the blade attachment means using two male protrusions, each of which would be positioned into each of the tube regions of the hockey shaft.

A hockey stick system of the present invention can be molded as a one piece structure with the blade portion attached, therefore producing an entire hockey stick. In this case, there is no joint between the shaft and the blade. The stick is made with longer prepreg tubes which are joined to the blade construction prior to molding. The entire stick with all components(shaft and blade) are molded together in one operation. It is also possible to have a precured blade, which is then placed in a mold for bonding to the prepreg shaft as it is cured. It is also possible to have a precured(or molded) shaft and blade, then place both into a mold with prepreg reinforcements wrapped around the joint or interface between the shaft and blade in order to make a one piece unit. The present invention can also be molded from 4 tubes as shown in Figure 9, with each tube occupying a quadrant of the hockey shaft cross section. This design allows the flexibility of creating openings in two directions: in line with the direction of travel of the blade for aerodynamic purposes as represented by openings 64b and 64d in Figure 11 , and perpendicular to the direction of travel of the blade for flexibility purposes as represented by openings 64a and 64c in Figure 11. With this design, it is also possible to locate both orientations of openings in the same location to give a truss like appearance to the hockey shaft. The corresponding insert would have a cross shaped cross section of insert 35 as shown in Figure 12 to properly fit into these openings.

Another option is to combine a single composite tube with a multiple tube composite design. In this example, the single composite tube can be a portion of the hockey stick shaft and co-molded with the multiple tubes to produce a lower cost alternative to a 100 % multiple tube construction. Another option is to combine the composite portion with a metal portion. In this example, the metal tube can be a portion of the hockey stick handle and fused or co-molded with the multiple prepreg tubes to produce a lower cost alternative to a 100 % carbon composite construction. This can produce a less expensive structure that can still achieve the performance and aesthetic requirements of the product.

Referring to Figs. 13-14, in order to make this construction, the forward ends 82 of a pair of prepreg tubes 80a, 80b, each having an inflatable bladder 84, are inserted into one end 85 of a metal tube 86. The unit is placed inside a mold having the same shape of the metal tube 86, at least at the juncture 70 of the prepreg tubes 80a, 80b and the metal tube 86. A pin or mold member (not shown) is placed between the prepreg tubes 80a, 80b where an opening 30 is to be formed. The mold is then closed and heated, as the bladders 84 are inflated, so that the prepreg tubes assume the shape of the mold, the mold member keeping the facing walls 71a, 71b apart so as to form the opening 30. As shown, the tubes 80a, 80b will form a common wall at seam 72. After the prepreg tubes have cured, the frame member 74 is removed from the mold, and the mold member or pin is removed, leaving the opening 30. In this embodiment, the seam 70 between the graphite portions 80a, 80b of the frame member 74 and the metal tube portion 86 should be flush. An insert can then be positioned in the opening 30.

The inserts can be molded into the structure when molding the composite stick handle, or positioned into the previously molded openings using adhesives.

The exterior walls of the inserts need not contact the interior walls of the openings on a continuous basis. For example, the walls of the inserts may be in partial contact with the interior walls of the openings. It is also possible for apertures to be formed between the exterior walls of the inserts and the interior walls of the openings.

The hockey stick system of the present invention is not limited to ice hockey stick systems. It can also be applied to field hockey stick systems. In fact, the aerodynamic benefits have a greater potential with field hockey because the frontal width of field hockey stick systems is much greater than ice hockey shafts.

The hockey stick system can also be applied to lacrosse sticks. Lacrosse sticks are very long in length and therefore carry significant frontal area and would benefit from the improved aerodynamics offered by the holes in the inserts.

As to the manner of usage and operation of the present invention, the same should be apparent from the above description. Accordingly, no further discussion relating to the manner of usage and operation will be provided.

With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention. Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.

Claims

1. A sport stick system comprising:

An elongated, at least generally straight handle adapted to be held by a player and a striking end adapted to contact and propel an object; the stick being fabricated of a relatively rigid material with limited flexibility; wherein the handle is formed of at least two hollow tubes, said tubes formed of composite material; wherein said handle has a longitudinal axis; wherein first portions of said tubes form an outer wall of said handle and define a handle interior; wherein second portions of said tubes extend across the interior of said handle and are bonded to one another along much of the length of said handle, thereby to form an internal reinforcing wall; and wherein said second portions are separated from one another at at least one axial location so as to form at least one opening; and an insert secured in said opening for varying the playing characteristics of the system.

2. The system as set forth in claim 1 wherein the stick is a hockey stick.

3. The system as set forth in claim 1 wherein the stick is a one piece hockey stick.

4. The system as set forth in claim 1 wherein the stick is a two piece hockey stick and wherein the striking end includes a blade separable from the shaft.

5. The system as set forth in claim 1 wherein the stick is fabricated of a composite material.

6. The system as set forth in claim 1 wherein the stick is fabricated of metal.

7. The stick as set forth in claim 1, wherein the insert includes a plurality of holes formed by a plurality of interior walls, one wall for each hole, the walls being parallel with respect to each other.

8. The stick as set forth in claim 1, wherein the insert has partial contact with the openings.

9. The stick as set forth in claim 1 wherein the stick is configured for ice hockey.

10. The stick as set forth in claim 1 wherein the stick is configured for roller hockey.

11. A composite hockey stick system for producing geometric shapes and improving the flexibility and strength and other playing characteristics of the system comprising, in combination: a stick handle fabricated of multiple layers of carbon filaments held together with an epoxy binder, the filaments of each layer being parallel to one another, the stick handle having a long generally hollow rectangular configuration having a top end, a bottom end, a front face, a bottom face, and a pair side faces, the stick handle having a central wall running axially and generally parallel with the side faces forming two adjacent tubes with hollow interiors along most the extent of the stick handle; a stick striking end fabricated of multiple layers of aligned carbon filaments held together with an epoxy binder, the stick striking end having a generally thin rectangular configuration with a first face, a second face, an upper edge, a lower edge, a near end, and a far end with the near end having a bend at an angle between 45 degrees and 80 degree and being preferably 65 degrees measured between the side faces of the stick handle end and the upper edge and the lower edge, wherein the near end of the stick handle end has one of a fitting extending outwardly therefrom and an opening, and the bottom end of the handle has the other of said fitting and said opening, said fitting being adapted to couple into the opening; an adhesive coupling the stick handle with the stick striking end between the connecting bar and the opening in the stick handle end; and at least one opening being formed in the stick handle and extending between the front face and the bottom face, each opening including an interior wall defining an associated hole, the openings and interior walls being aligned linearly along a central vertical axis of the stick tip end and being adjacent to bottom end, the openings separating the adjacent portions of the tubes of the stick handle end allowing for increased surface area, and; an insert structure inserted into said openings.

12. The stick as set forth in claim 1 , wherein the stick is a field hockey stick.

13. The stick as set forth in claim 1 , wherein the stick is a lacrosse stick.

14. The stick as set forth in claim 1 , wherein the stick is a polo mallet stick.

15. A stick as set forth in claim 1, wherein the striking end comprises a hockey blade, and wherein said internal reinforcing wall is oriented generally perpendicular to said blade so as to provide reinforcement to the handle when the blade propels an object.

16. A stick as set forth in claim 1, wherein said handle comprises more than two tubes.

17. A stick as set forth in claim 1, wherein said handle comprises four tubes forming two interior reinforcing walls which are at least generally perpendicular to one another.